REAR DIFFERENTIAL
When replacing a rear differential oil, select the correct one according to the following table.
Note. Using a different rear differential oil will cause the drive train and tires to drag or emit abnormal noise.
| Model | 2.5 L Non-turbo | |
|---|---|---|
| 4AT | 5MT | |
| Rear differential type | T-type | |
| Identification | TP | T2 |
| Type of gear | Hypoid gear | |
| Gear ratio (Number of gear teeth) | 4.444 (40/9) | 4.111 (37/9) |
| Oil capacity | 0.8 l (0.8 US qt, 0.7 lmp qt) | |
| Rear differential gear oil | GL-5 | |
REAR DIFFERENTIAL SPECIFICATION
| Model | 2.5 L Turbo |
|---|---|
| 4AT | |
| Rear differential type | T-type |
| Identification | B1 |
| Type of gear | Hypoid gear |
| Gear ratio (Number of gear teeth) | 4.111 (37/9) |
| Oil capacity | 0.8 l (0.8 US qt, 0.7 lmp qt) |
| Rear differential gear oil | GL-5 |
REAR DIFFERENTIAL SPECIFICATION
REAR DIFFERENTIAL GEAR OIL
Recommended gear oil
GL-5 (75W-90)
| CAUTION | Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. |
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SERVICE DATA
| Drive pinion bearing preload (For new bearing) | Measure with spring measurement. (Measured from the companion flange bolt) | N (kgf, lbf) | 17.7 - 38.8 (1.8 - 4.0, 4.0 - 8.7) |
|---|---|---|---|
| Measure with torque wrench | N.m (kgf-m, ft-lb) | 0.67 - 1.47 (0.07 - 0.15, 0.49 - 1.08) | |
| Side gear backlash | Mm (in) | 0.10 - 0.20 (0.004 - 0.008) | |
| Side bearing standard width | Mm (in) | 20.00 (0.7874) | |
| Hypoid driven gear to drive pinion backlash | Mm (in) | 0.10 - 0.20 (0.004 - 0.008) | |
| Hypoid driven gear runout on its back surface | Mm (in) | 0.05 (0.002) | |
SERVICE DATA
ADJUSTING PARTS
| Part No. | Length mm (in) | |
|---|---|---|
| Preload adjusting spacer | 383695201 | 56.2 (2.213) |
| 383695202 | 56.4 (2.220) | |
| 383695203 | 56.6 (2.228) | |
| 383695204 | 56.8 (2.236) | |
| 383695205 | 57.0 (2.244) | |
| 383695206 | 57.2 (2.252) |
PARTS SPECIFICATION
| Part No. | Thickness mm (in) | |
|---|---|---|
| Preload adjusting washer | 383705200 | 2.59(0.1020) |
| 383715200 | 2.57(0.1012) | |
| 383725200 | 2.55(0.1004) | |
| 383735200 | 2.53 (0.0996) | |
| 383745200 | 2.51 (0.0988) | |
| 383755200 | 2.49 (0.0980) | |
| 383765200 | 2.47 (0.0972) | |
| 383775200 | 2.45 (0.0965) | |
| 383785200 | 2.43 (0.0957) | |
| 383795200 | 2.41 (0.0949) | |
| 383805200 | 2.39 (0.0941) | |
| 383815200 | 2.37 (0.0933) | |
| 383825200 | 2.35 (0.0925) | |
| 383835200 | 2.33 (0.0917) | |
| 383845200 | 2.31 (0.0909) |
THICKNESS SPECIFICATION
| Part No. | Thickness mm (in) | |
|---|---|---|
| Pinion height adjusting washer | 383495200 | 3.09 (0.1217) |
| 383505200 | 3.12 (0.1228) | |
| 383515200 | 3.15 (0.1240) | |
| 383525200 | 3.18 (0.1252) | |
| 383535200 | 3.21 (0.1264) | |
| 383545200 | 3.24 (0.1276) | |
| 383555200 | 3.27 (0.1287) | |
| 383565200 | 3.30 (0.1299) | |
| 383575200 | 3.33 (0.1311) | |
| 383585200 | 3.36 (0.1323) | |
| 383595200 | 3.39 (0.1335) | |
| 383605200 | 3.42 (0.1346) | |
| 383615200 | 3.45 (0.1358) | |
| 383625200 | 3.48 (0.1370) | |
| 383635200 | 3.51 (0.1382) | |
| 383645200 | 3.54 (0.1394) | |
| 383655200 | 3.57 (0.1406) | |
| 383665200 | 3.60 (0.1417) | |
| 383675200 | 3.63 (0.1429) | |
| 383685200 | 3.66 (0.1441) | |
| Side gear thrust washer | 383445201 | 0.75 - 0.80 (0.0295 - 0.0315) |
| 383445202 | 0.80 - 0.85 (0.0315 - 0.0335) | |
| 383445203 | 0.85 - 0.90 (0.0335 - 0.0354) | |
| Side bearing retainer shim | 383475201 | 0.20 (0.0079) |
| 383475202 | 0.25 (0.0098) | |
| 383475203 | 0.30(0.0118) | |
| 383475204 | 0.40(0.0157) | |
| 383475205 | 0.50(0.0197) |
THICKNESS SPECIFICATION
| Drive pinion bearing preload | Measure with spring measurement. (Measured from the companion flange bolt) | N (kgf, lb) | 17.7 - 38.8 (1.8 - 4.0, 4.0 - 8.7) |
|---|---|---|---|
| Measure with torque wrench | N.m (kgf-m, ft-lb) | 0.67 - 1.47 (0.07 - 0.15, 0.49 - 1.08) | |
| Side gear backlash | Mm (in) | 0.10 - 0.20 (0.004 - 0.008) | |
| Hypoid driven gear to drive pinion backlash limit | Mm (in) | 0.10 - 0.20 (0.004 - 0.008) | |
| Hypoid driven gear runout limit on its back surface | Mm (in) | 0.05 (0.002) | |
DRIVE PINION BEARING PRELOAD SPECIFICATION
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CAUTION
- Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
- Remove contamination including dirt and corrosion before removal, installation or disassembly.
- Keep the disassembled parts in order and protect them from dust and dirt.
- Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
- Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
- Use SUBARU genuine gear oil, grease. Do not mix gear oil, grease, etc. of different grades or manufacturers.
- Be sure to tighten fasteners including bolts and nuts to the specified torque.
- Place shop jacks or rigid racks at the specified points.
- Apply gear oil onto sliding or revolving surfaces before installation.
- Before installing the O-ring or snap ring, apply a sufficient amount of gear oil to avoid damage and deformation.
- Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise.
- Avoid damaging the mating surface of the case.
GENERAL TOOL
| TOOL NAME | REMARKS |
|---|---|
| Transmission jack | Used for assembly/disassembly of the rear differential. |
| Puller | Used for removing the side bearing retainer. |
| Thickness gauge | Used for measuring clearance. |
GENERAL TOOL
AT MODEL
For front differential of automatic transmissions, refer to the "4AT" article. Refer to FRONT DIFFERENTIAL ASSEMBLY .
MT MODEL
For front differential of the manual transmission, refer to "5MT" article. Refer to FRONT DIFFERENTIAL ASSEMBLY .
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- Set the vehicle on a lift.
- Disconnect the ground cable from the battery.
- Shift the select lever or gear shift lever to neutral.
- Release the parking brake.
- Loosen the wheel nuts.
- Lift up the vehicle
- Remove the wheels.
- Remove the rear exhaust pipe and muffler. Non-turbo model Refer to «REMOVAL»(ref-325320-S35059142112009071800000) , Rear Exhaust Pipe. Refer to «REMOVAL»(ref-325320-S22382758332009071800000) , Muffler. Turbo model Refer to «REMOVAL»(ref-325336-S21151896522009071800000) , Rear Exhaust Pipe. Refer to «REMOVAL»(ref-325336-S04910540732009071800000) , Muffler.
- Remove the heat shield cover.
- Separate the rear differential side of the propeller shaft. NOTE: Make alignment marks on the flange yoke and rear differential before separating it.
- Remove the DOJ of rear drive shaft from rear differential. Remove the ABS wheel speed sensor cable from the clamp. Disconnect the connector and remove the nut to remove the rear vehicle height sensor. (models with auto headlight beam leveler, left side only) Remove the bolts which secure the rear stabilizer link to the rear lateral link. Remove the bolts which secure the shock absorber to the rear lateral link. Remove the bolts which secure the rear lateral link to the housing. Remove the bolts which secure the trailing link to the housing. Remove the DOJ from the rear differential by using ST. NOTE: When removing the DOJ from the rear differential, fit the ST to the bolts as shown in the figure so as not to damage the side retainer. ST 28099PA100 DRIVE SHAFT REMOVER
- Suspend the rear drive shaft to the rear cross-member using wire.
- Remove the rear differential front member.
- Support the rear differential with the transmission - jack.
- Remove the self-lock nuts which hold the rear differential to the rear crossmember.
- While slowly lowering the transmission jack, move the rear differential forward, and remove the rear differential from vehicle.
- Remove the rear differential member plate from rear differential.
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- Install the rear differential member plate to the rear differential.
- Set the rear differential to transmission jack.
- Adjust the transmission jack, and insert the rear differential stud bolt into rear crossmember bushing properly.
- After inserting the rear differential stud bolt into the rear crossmember bushing, lift up the transmission jack and align the rear differential to its attachment position.
- Tighten a new self-locking nut temporarily to rear crossmember.
- Install the rear differential front member with a new self-locking nut. Tightening torque: T1: 50 N.m (5.1 kgf-m, 36.9 It-lb) T2: 110 N.m (11.2 kgf-m, 81.1 ft-lb)
- Tighten the self-locking nut. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
- Attach the ST to rear differential. ST 28099PA090 OIL SEAL PROTECTOR
- Insert the spline shaft until the spline portion comes inside the side oil seal.
- Remove ST from rear differential. ST 28099PA090 OIL SEAL PROTECTOR
- Push the housing to insert DOJ completely into rear differential.
- Lower the transmission jack.
- Installing procedure hereafter is in the reverse order of removal.
- After installing, fill the differential carrier with gear oil up to the bottom of the filler plug hole. Refer to «DIFFERENTIAL GEAR OIL»(ref-325345-S00030987502009071800000) .
- Inspect the wheel alignment and adjust if necessary.
- Re-initialize the auto headlight beam leveler system. (models with auto headlight beam leveler) Refer to «PROCEDURE»(ref-325323-S27547444052009071800000) , Auto Headlight Beam Leveler System.
SIDE GEAR BACKLASH
Using a dial gauge, check the backlash of side gear.
Side gear backlash
0.10 - 0.20 mm (0.004 - 0.008 in)
If the side gear backlash is not within the specification, select the side gear thrust washer and adjust the side gear backlash as specified.
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HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of hypoid driven gear.
Hypoid driven gear backlash
0.10 - 0.20 mm (0.004 - 0.008 in)
If the hypoid driven gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.
HYPOID DRIVEN GEAR RUNOUT ON ITS BACK SURFACE
Using a dial gauge, check the hypoid driven gear back surface runout.
Hypoid driven gear back surface runout: 0.05 mm (0.002 in)
If the hypoid driven gear runout exceeds 0.05 mm (0.002 in), replace the hypoid driven gear.
TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between the hypoid driven gear and drive pinion. Refer to ASSEMBLY , Rear Differential.
TOTAL PRELOAD
Using a spring scale, check the total preload.
Total preload
20.7 - 54.4 N(2.1 - 5.5 kgf, 4.7 - 12.2 lbf)
If the total preload is not within the specification, adjust the side retainer shims.
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- If rust or dirt is attached to the companion flange, remove them.
- Set a dial gauge at a companion flange surface (mating surface of propeller shaft and companion flange), and then measure the companion flange runout. Limit of runout: 0.08 mm (0.003 in)
- Set the gauge inside of the companion flange, and measure the runout. Limit of runout: 0.08 mm (0.003 in)
- If either runout exceeds the limit, move the phase of companion flange and drive pinion 90° each, and find the point where the runout is within the limit.
- If the runout exceeds the limit after changing the phase, replace the companion flange and recheck the runout.
- If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.
Adjust the side gear backlash.
Refer to ASSEMBLY , Rear Differential.
Adjust hypoid driven gear backlash.
Refer to ASSEMBLY , Rear Differential.
Adjust the tooth contact between hypoid driven gear and drive pinion gear.
Refer to ASSEMBLY , Rear Differential.
Adjust the side retainer shim.
Refer to ASSEMBLY , Rear Differential.